BATCH FLOW PROCESS

Course Instructor Dr. N. Sambandam

_______________________________________________

NATIONAL INSTITUTE OF INDUSTRIAL ENGINEERING Vihar Lake, Mumbai 400 087.

PRODUCTS AND VOLUME Produce low volumes of variety of different products. Investment in specialized machines and tools is justified. Orders: one time for small qty. and repeat from time to time. Examples Home heating systems, Tanks for Examples: military, Ice cream, Forest harvest equipments, Suit coat, sport coat, Kitchen & dinning room furniture, Pharmaceutical products.

LAYOUT AND MATERIAL FLOW

Cellular layout/Functional layout. Employees work in more than one department and are skilled on many equipments. Equipment and tooling are special purpose a (lower overhead). Material flow through the shop do not differ for each job. Work-in-process inventory is low. Delivery times are not long. Setup time is low. Batch (or lot) size decides the workload in the shop. Scheduling is important but is simpler than job shop.

Reproducing the marker Materials ordering Fitting and Soabaring

To coat shop Cutting

Fitting

Materials receipts Spreading

To skirt shop

Fitting

sleeves Coat Shop fronts backs collars Welts, etc Major matching

Subassembly Subassembly Other subassembly Major matching Final assembly Pressing and inspection

Skirt shop

Serging

Remaining Skirt operations

Pressing and inspection

Warehouse matching Of coat and skirt To distributor

Outside pleating

Figure: a Simplified process flow diagram

Operation s flow chart

Button placket

Front pairing

Shoulder joint

Operations description
Work station #4 , operation: Trimming


 

 

A set of collar parts is taken from stand and put on the LHS area of the work station A collar neck band part is taken by left hand The part is put under the presser foot of trimming m/c by using both hands. The part is trimmed by machine by pivoting it wherever necessary The trimmed part is put on legs by right hand A batch of trimmed parts is taken from legs and put on the stand

Determination of smv & Throughput



Total smv= sum of all ten readings(seconds)/60 smv= Average smv= Total smv/10 smv= smv/10 Std time = Avg time(avg smv)*allowance time(avg smv)*allowance Allowance = 15% (for machine operation) = 12%(for manual operation) Capacity per hour(Throughput)= 60/std time

Path length path: collar to end line(length= 10.53 m)

Button placket

Front pairing

Shoulder joint

Path : collar band to end line checking length= 9.05 minutes

Button placket

Front pairing

Shoulder joint

Path: front right to end line checking path length= 9.62 minutes

Button placket

Front pairing

Shoulder joint

Path: front right to end line checking path length= 9.56 minutes

Button placket

Front pairing

Shoulder joint

Path: pocket to end line checking path length= 10.37 minutes

Button placket

Front pairing

Shoulder joint

Path: back to end line checking path length= 9.764 minutes

Button placket

Front pairing

Shoulder joint

Path: sleeve placket to end line checking path length= 8.68 minutes
Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Band set top

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach
Sleeve placket

Front pairing

Collar finishing

Pocket iron & trim

Small label attach
Sleeve Bartac

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach

Path: cuff to end line checking path length= 6.113 minutes

Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Band set top

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach
Sleeve placket

Front pairing

Collar finishing

Pocket iron & trim

Small label attach
Sleeve Bartac

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach

Critical path
The path having maximum time length i.e. if all the parts of the shirt are put into the line for their respective operations at the same time then the part which is coming through the path which is taking maximum time will decide the throughput time of the line , this path is called as critical path So here critical path: the path coming from collar to end line checking Critical path length= 10.53 minutes

Critical path critical path length=10.53 minutes

Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top
Band set top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach
Sleeve placket

Front pairing

Collar finishing

Pocket iron & trim

Small label attach
Sleeve Bartac

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach

Work balancing among work stations to achieve the required target

 

Search for the bottleneck operations Bottleneck decides the capacity of the line E.g. what is the capacity of this line?
Op1(100) Op2(90) Op3(115) Op4(120)

Work balancing .


continued

Operation with least capacity is sleeve placket SMV=1.18 minutes Capacity = 44 units per hour

But it will not be considered as bottleneck because it does not lie on the critical path

Critical path critical path length=10.53 minutes

Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top
Band set top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Collar attach

Pocket attach
Pocket iron
Main label attach Least Pocket capacity trim iron & SMV=1.1 8m& capacity Small label =44 u ph attach
Sleeve placket Sleeve Bartac

Front pairing

Collar finishing

PathCollar sleeve from inspection placket have the lead of 1.84 m over the critical path

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach

Work balancing
Next operation having the least capacity Cuff attach SMV = 1.145 minutes Capacity = 45 units per hour It lies on the critical path So considered as bottleneck operation So affects the line capacity, because changes in the smv value of this operation will have effect on critical path length

Work balancing.. Ways to improve bottleneck capacity

a.

Put an extra work station it will cause smv to be half and double the capacity Distribute the excess work to the other work stations(it is being applied currently)

b.

Distributing the excess work to other work stations in the line

   

Required capacity = 69 units per hour Current production = 45 units per hour Work remained= 69-45= 24 units per hour 69extra time required= 24*1.145*1.15= 31.6 minutes = 31 minutes 36 seconds Looking at the operation flow chart for the work station having operation running at over capacity Band hem is that operation capacity= 315 units per hour

Distribution of work

Band hem Minimum required units to be produced= 85 units per hour time required to do band hem operation on 85 units= (1/315)*85= 0.27 hours = 16.19 minutes = 16 minutes 11.4 seconds extra time available = 43 minutes 48.6 seconds For cuff attach we require 31 minutes 36 seconds So we can accommodate it here still time available = 12 minutes 12.5 seconds

Search for next bottleneck



Cuff run is the next operation having least capacity But it can t be said as a bottleneck operation because it doesn t lie on the critical path The sub path is having lead of 4.412 minutes over it s counter path on the junction operation So the delay caused by the cuff run operation will be compensated by the lead time

Operation = cuff run

Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Band set top

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach
Sleeve placket

Front pairing

Collar finishing

Pocket iron & trim

Pocket hem
Yoke attach
Sleeve box

Least capacity Small label = attach51uph smv=1.0 Sleeve 1m Bartac

Cuff run

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Sub path via cuff run is having lead time = 4.412 m over it s counter path

Checking & trimming

Button marking

Bottom hem

Cuff attach

    

 

 

Sleeve top Capacity=58 units per hour SMV= 0.88 minutes Extra units to be operationalised = 11 units per hour Time required to do sleeve top operation on 11 units = 11*0.88*1.15 = 11 minutes 8 seconds 3 options We can accommodate it on the work station at which band hem is being done Put an extra work station Search for another work station which is running on over capacity

Search for the next bottleneck

Search for the work station running at over capacity

    

 

Main label attachment Capacity = 206 units per hour SMV= 0.26 minutes Required capacity = 142 units per hour Time require for 142 unit = 142*1.15*0.26= 41 minutes 38.4 seconds Extra time available= 19 minutes 21.6 seconds So we can accommodate the 11 units per hour for the sleeve top operation Still the time available = 8 minutes 13 seconds

Improvement in the line capacity

 

Current capacity = 550 units per shift Projected improvement=10% or 56 units per shift New projected capacity = 606 units per shift Per hour capacity = 76 units So the bottleneck operation will be the operation running on the capacity less than 76 units per hour

Critical path length= 10.017 minutes

Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Band set top

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach
Sleeve placket

Front pairing

Collar finishing

Pocket iron & trim

Small label attach
Sleeve Bartac

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach

Operations with capacity <= 76 u p h

Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Band set top

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach
Sleeve placket

Front pairing

Collar finishing

Pocket iron & trim

Small label attach
Sleeve Bartac

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Sleeve attach

Yoke iron & trim

Sleeve button hole

Sleeve top

Side seam

Cuff hem
Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Cuff top
Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach

Bottleneck operations
Collar trim Collar run Collar trim Collar turn Collar edge level Collar iron Collar top

Placket trim

Front placket

Front button hole

Button placket

Band hem

Band set

Band set top

Collar attach

Collar inspection

Pocket attach
Pocket iron
Main label attach

Front pairing

Collar finishing

Pocket iron & trim

Small label attach
Sleeve Bartac

Pocket hem
Yoke attach
Sleeve box

Shoulder joint

Capaci ty = 69 u Sleeve attach ph

Cuff hem

Capaci Sleeve ty = placket 73 u ph

Front button attach

Cuff run

Cuff turn & edge

Collar & cuff button hole

Capaci ty = Sleeve button hole 75 u ph

Cuff top

Yoke iron & trim

Sleeve top

Capaci ty = 69 u ph

Side seam

Cuff matching and marking

Checking & trimming

Button marking

Bottom hem

Cuff attach